Method for production of phenol/acetone from cumene hydroperoxide

Abstract

A method is disclosed for the synthesis of phenol and acetone by acid-catalyzed decomposition over a catalyst comprising an acidic smectite clay, particularly an acidic montmorillonite silica-alumina clay. The method allows for quantitative conversions with yields of up to 98% mole or better. Further the method is capable of operating efficiently at high LHSVs.

What is claimed is: 
     
       1. In a method for cosynthesis of phenol and acetone by acid-catalyzed decomposition over a catalyst, the improvement comprising reacting cumene hydroperoxide over an acidic smectite clay catalyst at a temperature of about 20° C. to 150° C. and a pressure of from zero to 1000 psig. 
     
     
       2. The method of claim 1 wherein the smectite clay is an acidic montmorillonite silica-alumina clay possessing a stucture represented by:   M.sub.x/n.sup.n+ -yH.sub.2 O(Al.sub.4-x Mg.sub.x)(Si.sub.8)O.sub.20 (OH).sub.4     where M represents the interlamellar balancing cations from the group consisting of sodium or lithium and x, y and n are integers, and the acidities of said clay are in the range of 3 to 15 mg KOH/gm, or greater.   
     
     
       3. The method of claim 1 wherein the smectite clays are in a form from the group consisting of powders, granular forms or extruded forms. 
     
     
       4. The method of claim 1 wherein phenol/acetone are produced continuously and the feed liquid hourly space velocity (LHSV) is between 1 and 60 or greater. 
     
     
       5. The method of claim 1 wherein the temperature is between 40° and 120° C. 
     
     
       6. The method of claim 2 wherein the acidic clay has an acidity in the range of 3 to 15 mg KOH/gm, titrated to a phenolphthalein end point. 
     
     
       7. The method of claim 3 wherein the surface area of the catalyst is from 30 m 2  /g to 1000 m 2  /g. 
     
     
       8. The method of claim 7 wherein the surface area of the catalyst is from 200 m 2  /g to 1000 m 2  /g. 
     
     
       9. The method of claim 2 further comprising limiting the moisture content of the catalyst by heating to about 220° F. 
     
     
       10. The method of claim 2 wherein the operating pressure is from zero to 1000 psig. 
     
     
       11. The method of claim 2 wherein the operating pressure is from 100 psig to 400 psig. 
     
     
       12. The method of claim 2 wherein the cumene hydroperoxide feedstock is at least about 80% pure. 
     
     
       13. The method of claim 2 wherein the cumene hydroperoxide is diluted. 
     
     
       14. The method of claim 13 wherein the diluent is selected from the group consisting of acetone, a mix of acetone or cumene and phenol. 
     
     
       15. The method of claim 2 wherein the hydroperoxide conversions are 98 mole% or better. 
     
     
       16. The method of claim 2 wherein the total liquid hourly space velocity is one to 10, under mild conditions. 
     
     
       17. The method of claim 2 wherein there is no significant quantity of mesityl oxide by product formed.